WO2019185446A1 - Plaque de plâtre - Google Patents

Plaque de plâtre Download PDF

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Publication number
WO2019185446A1
WO2019185446A1 PCT/EP2019/057100 EP2019057100W WO2019185446A1 WO 2019185446 A1 WO2019185446 A1 WO 2019185446A1 EP 2019057100 W EP2019057100 W EP 2019057100W WO 2019185446 A1 WO2019185446 A1 WO 2019185446A1
Authority
WO
WIPO (PCT)
Prior art keywords
core
woven fabric
plasterboard
surface roughness
fibers
Prior art date
Application number
PCT/EP2019/057100
Other languages
English (en)
Inventor
Werner Huber
The-Dzu NGUYEN
Ilja DOROSCHENKO
Kati GEFFERS
Original Assignee
Etex Building Performance International Sas
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Etex Building Performance International Sas filed Critical Etex Building Performance International Sas
Publication of WO2019185446A1 publication Critical patent/WO2019185446A1/fr

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/14—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing calcium sulfate cements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
    • B32B13/02—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material with fibres or particles being present as additives in the layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
    • B32B13/14—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/08—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer the fibres or filaments of a layer being of different substances, e.g. conjugate fibres, mixture of different fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/04—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
    • E04C2/043—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres of plaster
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/03—3 layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—Fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—Synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0253—Polyolefin fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0261—Polyamide fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0261—Polyamide fibres
    • B32B2262/0269—Aromatic polyamide fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0276—Polyester fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/06—Vegetal fibres
    • B32B2262/062—Cellulose fibres, e.g. cotton
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/06—Vegetal fibres
    • B32B2262/062—Cellulose fibres, e.g. cotton
    • B32B2262/065—Lignocellulosic fibres, e.g. jute, sisal, hemp, flax, bamboo
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/14—Mixture of at least two fibres made of different materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10—Inorganic particles
    • B32B2264/101—Glass
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10—Inorganic particles
    • B32B2264/102—Oxide or hydroxide
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10—Inorganic particles
    • B32B2264/104—Oxysalt, e.g. carbonate, sulfate, phosphate or nitrate particles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10—Inorganic particles
    • B32B2264/107—Ceramic
    • B32B2264/108—Carbon, e.g. graphite particles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/306—Resistant to heat
    • B32B2307/3065—Flame resistant or retardant, fire resistant or retardant
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/538—Roughness
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2419/00—Buildings or parts thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2607/00—Walls, panels
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00612—Uses not provided for elsewhere in C04B2111/00 as one or more layers of a layered structure
    • C04B2111/0062—Gypsum-paper board like materials
    • C04B2111/00629—Gypsum-paper board like materials the covering sheets being made of material other than paper
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/20—Resistance against chemical, physical or biological attack
    • C04B2111/28—Fire resistance, i.e. materials resistant to accidental fires or high temperatures
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/92—Protection against other undesired influences or dangers
    • E04B1/94—Protection against other undesired influences or dangers against fire
    • E04B1/941—Building elements specially adapted therefor
    • E04B1/942—Building elements specially adapted therefor slab-shaped

Definitions

  • the present invention relates to plasterboards having a good fire resistance, and methods for the manufacture thereof.
  • Gypsum boards also known as drywall or plasterboards, are widely used in construction, in particular for partitions and ceilings.
  • the boards typically contain a gypsum core which is covered on each of its sides with a facer.
  • plasterboard provides a certain resistance to fire, as gypsum undergoes an endothermic dehydratation reaction when heated. It is known to further improve the fire resistance by using glass mat facers instead of paper facers, and/or by including fire resistant additives in the facers and/or core.
  • patent EP1303672 describes a fire-resistant plasterboard having a glass mat facer provided with a coating comprising hydrated alumina.
  • Patent application US 2003/0138614 describes a fire-resistant plasterboard wherein the core comprises vermiculite and hydrated alumina. There remains a need for other fire resistant plasterboards.
  • the boards described herein have a core which comprises additives for increasing the fire resistance, such as vermiculite and hydrated alumina.
  • the present inventors surprisingly found that the fire resistance of the boards can be increased further by providing the boards with an embossed facer.
  • a plasterboard comprising a core, said core having at least one side covered with a non-woven fabric having an inner side facing said core; wherein said core is obtained by setting of a mixture comprising a hydratable calcium sulfate, vermiculite, hydrated alumina, and water; and wherein said non-woven comprises an embossing pattern having a surface roughness Ra ranging from 15 pm to 60 pm on said inner side.
  • Aspect 2 The plasterboard according to aspect 1 , wherein said non-woven fabric comprises at least 50 wt% of glass fibers, based on the total fiber weight.
  • Aspect 3 The plasterboard according to aspect 1 or 2, wherein said non-woven fabric has surface roughness Ra ranging from 20 pm to 60 pm, preferably from 25 pm to 60 pm on said inner side.
  • Aspect 4 The plasterboard according to any one of aspects 1 to 3, wherein said non- woven fabric further has an outer side facing away from said core, said outer side having a surface roughness Ra of below 15 pm.
  • Aspect 5 The plasterboard according to any one of aspects 1 to 4, wherein said core is obtainable by setting of a mixture comprising:
  • Aspect 6 The plasterboard according to any one of aspects 1 to 5, wherein said core further comprises from 5 to 15 wt% of one or more clays.
  • Aspect 7 The plasterboard according to any one of aspects 1 to 6, wherein said core further comprises 0.2 wt% to 2 wt% of glass fibers.
  • Aspect 8 The plasterboard according to any one of aspects 1 to 7, wherein said non- woven fabric comprises an organic binder.
  • a method to provide a plasterboard according to any one of aspects 1 to 9, said method comprises the steps of:
  • Aspect 1 1. The method according to aspect 10, wherein said non-woven fabric has a surface roughness Ra ranging from 20 pm to 60 pm, preferably from 25 pm to 60 pm on said inner side.
  • Aspect 12 The method according to aspect 10 or 1 1 , wherein said aqueous slurry comprises:
  • Aspect 13 The method according to aspect 12, wherein said aqueous slurry further comprises:
  • Aspect 14 The use of a non-woven fabric provided with an embossing pattern having a surface roughness Ra ranging from 15 pm to 60 pm on at least one side, for increasing the fire resistance of a building board.
  • Aspect 15 The use according to aspect 14, wherein said side having an embossing pattern has a has a surface roughness Ra ranging from 20 pm to 60 pm, preferably from 25 pm to 60 pm.
  • plasterboard and“gypsum board” as used herein interchangeably and refer to a panel or board comprising a gypsum core, obtainable from a plaster slurry as described herein. Accordingly, the term“plasterboard” refers to a board or panel which is obtainable via the setting (hydration and hardening) of plaster.
  • board or “panel” as used herein refers to any type of wall, ceiling or floor component of any required size.
  • fiber means a material form characterized by a high ratio of length to diameter, preferably a length to diameter ratio of at least 50.
  • weight percentage (wt%), this is to be understood, unless differently specified, as the weight of the component expressed as percentage over the total weight of the composition in which the component is present.
  • a building board also referred to herein as“board”
  • board comprising a core having at least one side which is covered with a facer.
  • the board is adapted to provide good fire resistant properties.
  • the board is a plasterboard, wherein the core is obtained by setting a settable mixture comprising a hydratable calcium sulfate, vermiculite, and alumina trihydrate.
  • settable mixture comprising a hydratable calcium sulfate, vermiculite, and alumina trihydrate.
  • the facer is a non-woven fabric having an inner side facing the core, wherein the fabric is provided on that inner side with an embossing pattern. This will be explained further below.
  • the board will have a standard thickness ranging from 5 mm to 100 mm, preferably ranging from 10 mm to 30 mm, even more preferably ranging from 12 mm to 25 mm.
  • the board typically has a rectangular shape, although other shapes may also be envisaged.
  • the core of the board is obtained through the setting of a mixture comprising a hydratable calcium sulfate as known in the art.
  • a hydratable calcium sulfate refers to a partially dehydrated gypsum of the formula CaSCVxFhO, where x can range from 0 to 0.5.
  • the terms“plaster” and“hydratable calcium sulphate” are used interchangeably.
  • the term“calcium sulphate hemihydrate” is used.
  • dry weight when referred to plaster in a plaster composition, refers to the weight of the calcium sulphate including hydration water (i.e. the xH 2 0 of the above formula), but excluding the gauging water in the composition.
  • the“dry weight” of the settable mixture refers to the total dry weight of the components in the mixture, excluding free water.
  • Plaster can be obtained via the calcination of gypsum (i.e. calcium sulphate dehydrate or CaS04 * 2H 2 0), i.e. the thermal treatment of gypsum in order to remove (a part of) the combined water.
  • gypsum i.e. calcium sulphate dehydrate or CaS04 * 2H 2 0
  • natural or synthetic gypsum may be used. Natural gypsum may be obtained from gypsum rock or gypsum sand. Synthetic gypsum typically originates from flue gas desulphurization (FGD) or phosphonic acid production. Gypsum obtained from FGD is also known as desulphogypsum (DSG).
  • FGD flue gas desulphurization
  • DSG desulphogypsum
  • the mixture comprising the hydratable calcium sulfate is also referred to herein as “settable mixture” or“plaster slurry”.
  • the hydratable calcium sulfate is transformed to gypsum (calcium sulfate dihydrate). Accordingly, the core comprises gypsum.
  • the settable mixture preferably comprises 65 wt% to 85 wt% of hydratable calcium sulfate, more preferably from 70 w% to 80 wt%.
  • the hydratable calcium sulfate comprises at least 95 wt% of calcium sulfate hemihydrate, more preferably at least 98 wt%.
  • the settable mixture comprises 65 wt% to 85 wt% of calcium sulfate hemihydrate, more preferably from 70 w% to 80 wt%.
  • the settable mixture also comprises water.
  • the water is partially consumed in the transformation of the hydratable calcium sulfate to gypsum. Most of the remaining water is then removed via drying, such that the core comprises (almost) no free water (i.e. water that is not hydration water).
  • the settable mixture comprises water; wherein the water to plaster ratio (i.e. the ratio of the weight of water vs. the dry weight of plaster) of the settable mixture is between 0.7 and 1.0. In preferred embodiments, the water to plaster ratio of the settable mixture is between 0.75 and 0.95. In particularly preferred embodiments, the water to plaster ratio of the settable mixture is between 0.80 and 0.90.
  • the water to plaster ratio i.e. the ratio of the weight of water vs. the dry weight of plaster
  • the settable mixture used to prepare the core also comprises vermiculite to increase the fire resistance of the core.
  • Vermiculite is an aluminium-iron-magnesium silicate which expands at a temperature above 200° C.
  • the vermiculite present in the core is unexpanded vermiculite, i.e. vermiculite in its unexpanded or non-exfoliated form.
  • the vermiculite can compensate for shrinkage of the gypsum.
  • the vermiculite can also improve the thermal resistance of the gypsum.
  • the vermiculite is provided as particles wherein at least 99.5% (by weight) of the particles are less than 1 mm in size. This facilitates distribution of the vermiculite in the settable mixture, and avoids an abrupt expansion causing structural disorders.
  • the settable mixture comprises between 1 wt% and 6 wt% of vermiculite (based on the dry weight of the settable mixture); preferably between 2 wt% and 5 wt%; and more preferably between 2.5 wt% and 4.5 wt%.
  • the settable mixture used to prepare the core also comprises hydrated alumina (AI(OH) 3 - also known as aluminium hydroxide, aluminium trihydroxide, or alumina trihydrate). It increases the fire resistance of the core as it gives rise to an endothermic reaction complementary to that of gypsum when heated. Hydrated alumina is preferably used with a fine particle size (median diameter of about 10 pm).
  • the settable mixture comprises between 2 wt% and 15 wt% of hydrated alumina (based on the dry weight of the settable mixture); preferably between 3 wt% and 12 wt%; and more preferably between 4 wt% and 10 wt%.
  • the settable mixture may comprise one or more clays (other than vermiculite).
  • the advantages afforded by clays are, on the one hand, the fact that they release the water that they contain (water of constitution) when they are heated to a temperature between 100 and 600 °C, and, on the other hand, the fact that they compensate for the shrinkage of the gypsum in a fire because of their ability to exfoliate.
  • the one or more clays preferably are aluminium phyllosilicates, more preferably selected from the group consisting of kaolinite, illite, halloysite, montomohllonite, talc, sepiolite, palygorkite, and pyrophyllite.
  • Preferred clays are kaolinite and/or illite. Most preferably, the clay is or comprises kaolinite.
  • the settable mixture comprises between 5 wt% and 20 wt% of one or more clays (based on the dry weight of the settable mixture); preferably between 8 wt% and 15 wt%.
  • the settable mixture may comprise a combination of one or more clays as described above, with one or more polysiloxanes or silicones.
  • a synergy between clays and polysiloxanes can result in significantly improved water repellant properties of the resulting board.
  • the total weight of the one or more silicones is between 0.5 wt% and 10 wt%, based on the total weight of the one or more clays. In further embodiments, the total weight of the one or more silicones is between 1 wt% and 5 wt%, based on the total weight of the one or more clays.
  • the settable mixture may comprise glass fibers.
  • Glass fibers can impart high-temperature mechanical strength.
  • the fibers preferably are made of an E-type glass.
  • the fibers preferably have an average length (number average) ranging from 3 mm to 24 mm.
  • glass fibers having a single length of 13mm ⁇ 5 mm are used.
  • the glass fibers preferably have a diameter ranging from 5 pm to 20 pm, preferably from 8 pm to 18 pm.
  • the settable mixture comprises between 0.2 wt% and 2 wt% of glass fibers (based on the dry weight of the settable mixture); preferably between 0.5 wt% and 1.5 wt%.
  • the settable mixture may further comprise other additives as is known in the art, such as foaming agents, fluidizers, starch, fillers, accelerants, set retarders, pigments, and anti sagging agents.
  • additives such as foaming agents, fluidizers, starch, fillers, accelerants, set retarders, pigments, and anti sagging agents.
  • the core may comprise starch.
  • the starch may be natural starch; or a starch derivative such as a substituted starch.
  • the starch may be derived from e.g. potato, tapioca, or corn. Starches are often used to improve the adhesion of a facer to a core.
  • the settable mixture comprises:
  • the settable mixture comprises:
  • the core of the board may have a low to high density, depending on the envisaged use.
  • the core has a bulk density between 750 kg/m 3 and 1100 kg/m 3 ; preferably between 800 kg/m 3 and 1000 kg/m 3 .
  • the core of the board comprises
  • the core may further comprise from 5 wt% to 15 wt% of one or more clays as described above.
  • the core may further comprise from 0.2 wt% to 2 wt% of glass fibers.
  • the board described herein typically has two opposing faces or sides. At least one of the faces is provided with a liner or facer. More preferably, both faces are provided with a liner. Both faces of the board may be provided with the same type of liner, or a different type.
  • a liner which comprises a non-woven fabric, also referred to herein as“non-woven mat”, or simply as “fabric”,“mat”, or“web”.
  • the non-woven fabric has an inner side facing the core of the board, wherein the fabric is provided with an embossing pattern on the inner side.
  • both of the opposing sides are provided with such a liner.
  • the gypsum of the core may penetrate partly in the facer, but the facer is generally not fully embedded in the core. Accordingly, the outer side of the facer (i.e. the side facing away from the core) typically forms the surface of the board. This allows folding of the board, e.g. for covering corners. In such applications, one or more cuts may be made on the backside of the board, through the entire core but not through the facer. Non-limiting examples of such applications are described in patent EP1719851.
  • the non-woven fabric is described further herein below.
  • non-woven fabric means a fabric-like material made from fibers, bonded together by chemical, mechanical, heat or solvent treatment.
  • “Non-woven fabrics” can define sheets supports or web structures bounded together by entailing fibers or filaments.
  • Non-woven fabrics can be prepared according to well-known processes such as water laying (wet-laying), meltblowing, spin laying, carding, and air laying.
  • the fibers are chemically bonded, more particularly via a binder.
  • the binder may be organic or inorganic.
  • the binder is an organic binder, more particularly a polymer-based binder. Suitable binders are known in the art.
  • a latex binder is used selected from the group consisting of vinyl acrylic, ethylene polyvinyl acetate, polyvinyl acetate, styrene butadiene, styrene acrylic, acrylic, or mixtures thereof. Particularly preferred are vinyl-acrylic copolymers.
  • the non-woven fabric may further comprise one or more fillers, preferably mineral fillers.
  • suitable fillers include calcium carbonate, calcium sulfate (anhydrite, hemihydrate, or dihydrate), clay (e.g. kaolin), sand, talc, mica, glass powder, titanium dioxide, magnesium oxide, alumina, alumina trihydrate, silica, silicate, and carbon.
  • the dimensions of the filler are typically such that it substantially penetrates into the fibrous mat.
  • the mineral filler could be particles that have a volume- basis median particle size (dso) from about 0.1 pm to about 10 pm, preferable about 0.5 pm to 5 pm.
  • the particle size is an equivalent spherical diameter as measured with laser diffraction, such as described in ISO 13320:2009.
  • the particles are dispersed in air (dry form) and a laser is passed through the dispersed particles.
  • the intensity of the scattered light at different angles is collected.
  • the span of the particle size distribution is between 1 and 3.
  • the non-woven fabric may further be provided with various additives such as water resistant or water repellent agents, biocides, fire resistant agents and/or pigments, as known in the art.
  • the non-woven fabric is preferably made of fibers having a length from 1.0 mm to 40 mm.
  • the average length of the fibers can vary from 10 mm to 38 mm.
  • the fibers may be a mixture of fibers having different length.
  • the fibers of the non-woven fabric can be made of various materials.
  • the fibers in the fabric can all be made of the same material, or the fabric may contain a mixture of fibers made from different materials.
  • the fibers are preferably selected from mineral fibers, organic fibers, synthetic (polymeric) fibers, and mixtures thereof.
  • the non-woven fabric comprises mineral fibers, preferably glass fibers.
  • the use of glass fibers allows for a better fire resistance of the board.
  • the non-woven fabric may comprise at least 30 wt% of glass fibers, based on the total fiber weight of the fabric.
  • the non-woven fabric comprises at least 50 wt%, at least 75 wt%, or even at least 90 wt% of glass fibers, based on the total fiber weight of the fabric.
  • the glass fiber diameter can vary within broad ranges, for example from 2.0 pm to 40.0 pm.
  • glass fibers have an average diameter below 40pm, preferably below 25pm, more preferably from 8 pm to 25pm. Mixtures of fibers of different fiber diameters (and length) can be used.
  • the non-woven fabric comprises synthetic fibers.
  • suitable synthetic fibers include polyester fibers, polyamide fibers, polyaramide fibers, polyethylene fibers, and polypropylene fibers.
  • polyester fibers are used.
  • the non-woven fabric comprises organic fibers.
  • suitable organic fibers may be cellulose based fibers, such as flax, wood pulp, cotton, sisal, abaca, viscose, rayon and/or lyocel fibers.
  • the non-woven fabric may comprise a combination of mineral fibers, synthetic organic fibers, and organic fibers as described above.
  • the fabric may comprise a combination of glass fibers, cellulose fibers, and polyester fibers. Such fabrics can provide an improved wet tensile strength, better bonding between inner ply and gypsum core and excellent fire resistance properties.
  • the non-woven fabric may comprise one or more layers or plies of non-woven material.
  • the non-woven fabric is made of a single ply of non-woven material.
  • the non-woven fabric may comprise an inner ply and an outer ply.
  • The“inner ply” is the ply that contacts the gypsum core of the board.
  • The“outer ply” is the ply that is or is intended to be farther from the gypsum core, i.e. located in the external side of the plasterboard and thus facing away from the core. Accordingly, the outer ply typically is in contact with the exterior and can be painted, covered with tiles or finished in another usual way.
  • These two plies may have the same composition or a different composition.
  • the outer and inner ply have different compositions.
  • Such a two ply configuration provides the advantage of allowing to design an asymmetrical fibrous mat with one outer ply being optimized for safer handing and compatibility with finishing and adhesive products, and with an inner ply being optimized for an improved fire resistance and strong and durable mechanical bonding with the gypsum core.
  • the outer ply is made of at least 90 wt% cellulose fibers and/or synthetic fibers (based on the total fiber weight of the outer ply); whereas the inner ply is made of at least 35 wt% glass fibers (based on the total fiber weight of the inner ply).
  • the inner ply may comprise at least 50 wt%, at least 75 wt%, at least 85 wt%, or even at least 90 wt% of glass fibers (based on the total fiber weight of the inner ply).
  • the non-woven fabric is provided with an embossing pattern on at least the inner side, which is in contact with the gypsum core.
  • the present inventors surprisingly found that the presence of an embossing pattern on the inner side helps increasing the fire resistance of the boards. Without wishing to be bound by theory, the inventors believe that this is linked to the increased surface roughness of the embossed fabric. Indeed, it was previously found that the embossing process leads to a reorientation of the fibers of the non-woven material, which leads to an increased surface roughness compared to the unembossed surface. This is further described in international patent application WO 2013/1 13459, wherein the increased surface roughness is utilized for improving the adherence between core and facer. The present inventors on the other hand, now found that the embossing pattern can be provided for increasing the fire resistance of plasterboard.
  • the inner side of the non-woven fabric has a surface roughness Ra of at least 15 pm, preferably at least 20 pm, more preferably at least 25 pm.
  • the surface roughness Ra of the inner side preferably is not higher than 60 pm.
  • the inner side has a surface roughness Ra ranging from 25 pm to 60 pm.
  • the Ra surface roughness parameter corresponds to the arithmetic mean of the absolute values of the profile deviations from the mean line of the roughness profile.
  • the surface roughness is a parameter well known in the art and can be measured using an optical profilometer.
  • the Ra surface roughness parameter is measured in accordance with DIN ISO 4287, with a measurement length of 3.5 mm, and 500 measuring points per mm. The reported value is the mean of 6 measurements.
  • the embossing pattern may also be provided on the outer side of the non-woven fabric.
  • the outer side is not provided with the embossing pattern.
  • the outer side of the non-woven fabric also has a lower roughness than the inner side.
  • the surface roughness Ra of the inner side preferably is below 15 pm, more preferably below 13 pm, even more preferably below 12 pm.
  • the surface roughness Ra of the inner and outer side of the non-woven fabric are above 15 pm and below 15 pm respectively; preferably above 20 pm and below 15 pm respectively; and more preferably above 20 pm and below 13 pm respectively. In specific embodiments, the surface roughness Ra of the inner and outer side of the non-woven fabric are above 25 pm and below 12 pm, respectively.
  • the non-woven fabric comprises two or more plies, then at least the inner ply is provided with an embossing pattern as described above. The other plies may or may not be provided with the embossing pattern.
  • the inner ply is provided with the embossing pattern, but the outer ply not.
  • the non-woven fabric is preferably obtained by a process comprising wet laying a suspension of fibers onto a screen or a screen assembly with the addition of a binder composition so as to form a web; and draining water from the web to produce a mat facer.
  • a process comprising wet laying a suspension of fibers onto a screen or a screen assembly with the addition of a binder composition so as to form a web; and draining water from the web to produce a mat facer.
  • screen means a material made with a certain defined kind of yarns and mesh or wire.
  • the non-woven fabric is formed onto the screen by a de watering step.
  • a screen assembly For obtaining the embossing pattern on the inner side, it is preferred to use a screen assembly, more particularly a double screen assembly.
  • the double screen assembly results from the superposition of a first base screen and a second screen, onto which the wet laid non-woven fabric is formed.
  • the inner ply is directly laid onto the second screen, and the outer-ply of the facer is formed over the inner ply.
  • the facer of the board, and in particular the non-woven fabric thereof is obtainable via a process comprising wet laying a suspension of fibers onto a double screen assembly so as to form an (embossed) web; and draining water from the web.
  • the process typically also comprises the step of drying the web.
  • the process typically also comprises an impregnation step, wherein the web is impregnated with a solution comprising the binder. Accordingly, in particular embodiments, the process may comprise the following steps:
  • the impregnation step is advantageously made in a size press.
  • step (a) may involve the wet laying of more than one suspension of fibers. More particularly, step (a) may comprise:
  • the (double) screen assembly comprises a first base screen and a second screen superimposed on the first screen.
  • the second screen comprises coarser yarns and coarser meshes compared to the yarns and meshes of the first screen.
  • the superimposed screens modify the orientation of the fibers when water is drained through the openings of the coarser mesh.
  • the number of weft and warp yarns/cm of the first base screen is greater than that of the second screen.
  • the first base screen contains at least more than 4 times weft and warp yarns/cm than the second screen.
  • the first base screen comprises from 15 to 50 weft yarns/cm preferably from 20 to 35 weft yarns/cm, more preferably 32 weft yarns/cm, and from 15 to 50 warp yarns/cm, preferably from 20 to 35 warp yarns/cm, more preferably 32 warp yarns/cm;
  • the second screen comprises from 1 and 15 weft yarns/cm, preferably, 7 weft yarns/cm, and from 1 and 15 warp yarns/cm, preferably around 6,3 warp yarns/cm;
  • the ratio of apertures per cm 2 between the first and the second screen is at least 10, advantageously around 23.2.
  • the diameter of the weft yarns of the first base screen is smaller than the diameter of the warp yarns of the first base screen.
  • the first base screen comprises weft yarns having a diameter from 0.1 mm and 0.4 mm, advantageously equal to 0.18 mm, and warp yarns having a diameter from 0.1 mm and 0.4 mm advantageously around 0.22 mm;
  • the second screen comprises weft yarns having a diameter from 0.3 and 1.2 mm, advantageously about 0.7 mm, and warp yarns having a diameter from 0.3 and 1.2 mm, advantageously about 0.75 mm.
  • the solution comprising the binder used in step (d) may further comprise one or more fillers, and/or other additives as described above.
  • the solution When comprising fillers, the solution typically forms a slurry.
  • the dry content of the slurry preferably ranges from 10 wt% to 50 wt%.
  • the board can be manufactured using standard processes known for the manufacture of plasterboard. Such processes typically comprise the deposition of a plaster slurry onto a facer material, forming the slurry into a panel; and allowing the panel to set.
  • the board described herein may be manufactured via a process comprising:
  • the slurry of step (i) may be prepared by mixing plaster with water and the other components of the slurry in a mixer as is known in the art. Suitable amounts of the main components (water, plaster, vermiculite, hydrated alumina) in the slurry or settable mixture are as described above.
  • the facer material used in step (ii) is a facer material as described above.
  • step (iii) the plaster composition is formed into a panel.
  • the slurry is deposited on the facer material.
  • a second facer material (which may be identical or not to the facer material of step (ii)) on top of the slurry, so that the slurry is sandwiched between the facers.
  • the slurry is formed or pressed into a panel.
  • the panel produced in step (iii) typically is of indefinite length, and will be cut to the required size.
  • step (iv) the panel obtained in step (iii) is allowed to set. More particularly, the plaster in the panel is allowed to set. This is well known in the art.
  • the method described herein will also comprise a step (v) of drying the panel.
  • the drying step most of the resulting free water is removed from the core. Drying is typically performed in a drier at elevated temperature; preferably the drier temperature is set between 100°C and 250°C. The actual temperature of the plasterboard during drying preferably does not exceed 100°C. Drying typically occurs after the setting of the panel. More particularly, the rehydration rate is preferably as close as possible to 100%, preferably at least 97%. Further provided herein is the use of a non-woven fabric as described above, for increasing the fire resistance of a building board.

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Abstract

La présente invention concerne une plaque de plâtre ayant une résistance accrue au feu. La plaque de plâtre comprend une âme, ladite âme ayant au moins un côté recouvert d'une étoffe non tissée ayant un côté interne faisant face à ladite âme. Ladite âme est obtenue par la prise d'un mélange comprenant un sulfate de calcium hydratable, de la vermiculite, de l'alumine hydratée et de l'eau. Ladite étoffe non tissée comprend un motif de gaufrage ayant une rugosité de surface Ra allant de 15 µm à 60 µm sur ledit côté interne.
PCT/EP2019/057100 2018-03-26 2019-03-21 Plaque de plâtre WO2019185446A1 (fr)

Applications Claiming Priority (2)

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EP18163973.3 2018-03-26
EP18163973 2018-03-26

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WO2022101472A1 (fr) * 2020-11-16 2022-05-19 Etex Building Performance International Sas Panneau résistant au feu léger et stratifié pour applications marines

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